Spring-Return Pneumatic Linear Actuator...3 Installation, Operation and Maintenance Manual MAN 617...

Installation, Operation and Maintenance Manual MAN 617 Rev. 6

August 2020

Biffi PLAS Spring-Return Pneumatic Linear Actuator

Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – [email protected]

August 2020

Installation, Operation and Maintenance ManualMAN 617 Rev. 6

Revision Details

Revision Details

Revision Details

Rev. Date Description Prepared Checked Approved

6 August 2020 Updated cover image

5 June 2020 General update (Migration to new template)

4 May 2018 Updated Data-plate Ermanni Orefici Vigliano

3 April 2016 Updated applicable regulation (Section 1.1.1) Ermanni Orefici Vigliano

2 August 2014 General update Ermanni Cristalli Vigliano

1 October 2009 General update Ermanni Soto Vigliano

0 May 1999 Document release Lazzarini Aliani Ziversi

iTable of Contents

Installation, Operation and Maintenance Manual MAN 617 Rev. 6

Table of ContentsAugust 2020

Table of Contents

Section 1: General Warnings1.1 Generalities ................................................................................................. 1

1.1.1 Applicable Regulation ....................................................................... 11.1.2 Terms and Conditions ....................................................................... 2

1.2 Identification Plate ...................................................................................... 21.3 Introducing the Actuator ............................................................................ 31.4 Data Sheet .................................................................................................. 4

Section 2: Installation2.1 Checks Upon Actuator Receipt .................................................................... 52.2 Actuator Handling ...................................................................................... 52.3 Storage ....................................................................................................... 62.4 Actuator Assembly on the Valve .................................................................. 7

2.4.1 Types of Assembly ............................................................................ 72.4.2 Assembly Procedure ......................................................................... 7

2.5 Pneumatic Connections ............................................................................ 122.6 Electrical Connections (If Any) ................................................................... 122.7 Commissioning ......................................................................................... 13

Section 3: Operation and Use3.1 Operation Description ............................................................................... 143.2 Residual risks ............................................................................................. 153.3 Operations ................................................................................................. 15

3.3.1 Local Pneumatic Operation ............................................................. 153.3.2 Electric Remote Control to Open and to Close ................................ 163.3.3 Emergency Manual Operation by MSJ / MH ........................................ 163.3.4 Emergency Manual Operation by MHP ............................................... 17

3.4 Calibration of the Linear Stroke.................................................................. 173.5 Calibration of Micro-Switches (for Biffi limit switch box*) .......................... 203.6 Calibration of the Operation Time ............................................................. 22

Section 4: Operational Tests and Inspections Operational Tests and Inspections ............................................................ 24

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Table of Contents

Table of Contents

Section 5: Maintenance5.1 Periodic Maintenance ................................................................................ 25

5.1.1 Check and Restore Oil Level In The Gas-Hydraulic Tanks .................. 265.1.2 Gas Supply Dehydrating Filter Maintenance (if foreseen) ................. 28

5.2 Extraordinary Maintenance ....................................................................... 285.2.1 Replacement of Cylinder Seals ........................................................ 28

5.3 Dismantling and Demolition ..................................................................... 33

Section 6: Troubleshooting6.1 Failure or Breakdown Research ................................................................. 34

Section 7: Layouts7.1 Spare Parts Order ...................................................................................... 357.2 Parts List for Maintenance and Replacing Procedure .................................. 36

Section 8: Date Report for Maintenance Operations Date Report for Maintenance Operations .................................................. 46

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Installation, Operation and Maintenance ManualMAN 617 Rev. 6 August 2020

Section 1: General Warnings

General Warnings


NOTICEThe manual is an integral part of the machine, it should be carefully read before carrying out any operation and it should be kept for future references.

1.1 Generalities

Biffi Italia s.r.l. actuators are conceived, manufactured and controlled according to the Quality Control System in compliance with EN-ISO 9001 international regulation.

1.1.1 Applicable Regulation

EN ISO 12100:2010: Safety of machinery – General principles for design – Risk assessment and risk reduction

2006/42/EC: Machine directive

2014/68/EU: Directive for pressure PED equipment

2014/35/EU: Directive for low voltage equipment

2014/30/EU: Directive for the electromagnetic compatibility

2014/34/EU: Directive and safety instructions for use in hazardous area

NOTICEBiffi Italia s.r.l. pays the highest attention to collecting and verifying the documentation contained in this user manual. However Biffi Italia s.r.l. is not liable for any mistakes contained in this manual, for damage or accidents due to the use of the latter. The information contained is of exclusive reserved ownership of Biffi Italia s.r.l. and may be modified without prior notice. All rights reserved.

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General Warnings

1.1.2 Terms and Conditions

Biffi Italia s.r.l. guarantees that all the items produced are free of defects in workmanship and manufacturing materials and meet relevant current specifications, provided they are installed, used and serviced according to the instructions contained in the present manual. The warranty can last either one year from the date of installation by the initial user of the product, or eighteen months from the date of shipment to the initial user, depending on which event occurs first. All detailed warranty conditions are specified in the documentation forwarded together with the product. This warranty does not cover special products or components not warranted by subcontractors, or materials that were used or installed improperly or were modified or repaired by unauthorized staff. In the event that a fault condition be caused by improper installation, maintenance or use, or by irregular working conditions, the repairs will be charged according to applicable fees.

The warranty and Biffi Italia s.r.l. liability shall lapse in the event that any modification or tampering whatsoever be performed on the actuator.

1.2 Identification Plate

It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia s.r.l.

The plate fastened on the actuator contains the following information (Figure 1).

Figure 1 Data Plate

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General Warnings

1.3 Introducing the Actuator

PLAS Spring-Return Pneumatic Low-Pressure Linear Actuators, are suitable for the operation of linear valves (wedge gate valves, through conduit gate valves) for ON-OFF and modulating heavy-duty service.

The actuator is made up of a pneumatic cylinder, a spring cartridge and a mounting pedestal complete with a joint for the coupling to the valve stem of actuator output stem.

The valve is actuated in opening and in closing position by the actuator pneumatic cylinder in one direction and by the spring unit in the other direction. The output thrust of spring unit can be downward or upward according to valve operation requirements (spring to open, spring to close, direct acting valve, reverse acting valve). The spring-return pack incorporates up to four spring , fully encapsulated in a factory welded cartridge: this assures safety conditions to personnel and simplifies the assembly. The linear stroke of the valve is adjustable by means of the external mechanical stop and by the adjustment of the coupling of valve stem to actuator joint. The actuator pedestal has a flange with threaded holes to fix the actuator to the valve.

Biffi can supply different types of control system following Customer’s requirements.

The expected lifetime of actuator is approximately 25 years.

Figure 2 Identification of Actuator Parts

Manual handpump MHP (optional)

Pneumatic cylinder

Lifting eyelets

Hydraulic cylinder (for MHP models)

Valve coupling

Valve position indicator

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General Warnings

1.4 Data SheetSupply fluid Air, Nitrogen or sweet gas

Operating temperature Standard: from –30 °C to +100 °C Optional: from –60 °C to +140 °C For working temperature please refer to technical

document: “actuator data sheet”

Supply pressure Please refer to technical document: “actuator data sheet”

Table 1.

PLAS 250k 585 100k 300 CL MHW

Manual override

Spring action

Stroke (mm)

Spring ending thrust (N)

Cylider diameter (mm)

Max. allowable thrust (N)

Spring-return actuator

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Section 2: Installation

Installation

2.2 Actuator Handling

NOTICEThe lifting and handling should be made by qualified staff and in compliance with the laws and provisions in force.

!WARNINGThe fastening points are appropriate for the lifting of the actuator alone and not for the valve + actuator assembly. Avoid that during the handling, the actuator passes above the staff. The actuator should be handled with appropriate lifting means. The weight of the actuator is reported on the delivery bill.

For a correct lifting procedure, please refer to following Figures.

Figure 3 Lifting Points for PLAS Actuators

1 = Lifting points (obligatory)


2.1 Checks Upon Actuator Receipt

• Check that the model, the serial number of the actuator and the technical data reported on the identification plate correspond with those of order confirmation, see Section 1.2.

• Check that the actuator is equipped with the fittings as provided for by order confirmation.

• Check that the actuator was not damaged during transportation: if necessary renovate the painting according to the specification reported on the order confirmation.

• If the actuator is received already assembled with the valve, its settings have already been made at the factory.

• If the actuator is delivered separately from the valve, it is necessary to check, and if required, to adjust, the settings of the mechanical stops (refer to Section 3.4) and of micro-switches (if any) refer to Section 3.5.

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Installation

2.3 Storage

If the actuator needs storage, before installation follow these steps:

• Place it on a wood surface in order not to deteriorate the area of valve coupling.

• Make sure that plastic plugs are present on the hydraulic and electrical connections (if present).

• Check that the protection of the control system and of the limit switch box (if any) are properly closed.

If the storage is long-term or outdoor:

• Keep the actuator protected from direct weather conditions.

• Replace plastic plugs of hydraulic and electrical connections (if any) with metal plugs that guarantee perfect tightness.

• Coat with oil, grease or protection disc, the valve coupling area.

• Periodically operate the actuator, refer to Section 3.3.

Figure 4 Positioning by Chains

1. Point of support

2. Don’t lay the actuator on tie-rods of cylinder.

3. Don’t lay the actuator on accessories (manual handpump, manual jackscrew, pneumatic control system, etc.).

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Installation

2.4 Actuator Assembly on the Valve

2.4.1 Types of Assembly

The adapter pedestal in fabricated carbon steel is specifically designed for adaptation to any type of valve with provision for local indicator, limit switches and other accessories (on request).

Lift the actuator by safety hook for chains using the lifting points (see Section 2.2) on the top of actuator for handling, transporting and assembling in vertical position (see Figure 3). For handling, transporting and assembling the actuator in horizontal position by safety hook for chains use the lifting points on the top of cylinder head flange and on coupling flange (see Figure 4).

2.4.2 Assembly Procedure

!WARNINGFailure to comply with the following procedures may impair product warranty. Installation, commissioning and maintenance and repair works should be carried out by qualified staff. A non-conforming assembly could be the source of serious accidents.

For actuator assembly on the valve:

NOTICECheck that the assembly position, as shown on the documentation, complies with sys-tem’s geometry. Check the consistency of the parts of actuator-valve coupling.

8

9

8

7

6

5

4

2

1

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Installation

A. To assemble the actuator onto the valve by bracket with threaded joint proceed as follows:

Table 1. Parts List

Item Description

1 Nut

2 Stud bolt

3 Support joint

4 Index

5 Screw

6 Connecting joint

7 Screw

8 Bushing

9 Flange

Figure 5 Pedestal with Threaded Coupling Joint

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Installation

1. Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions (valve stem and flange). Lubricate the valve stem with grease in order to make the assembly easier.

2. Connect a sling to the support point of the actuator and lift it. To make easier the assembly, the valve stem has to be in perfect vertical position.

NOTICEThe eyebolt is sized for the lifting of the only actuator (NOT ACTUATOR+VALVE). Proper lifting points have to be foreseen for the valve.

3. Screw the actuator coupling joint onto the valve by rotating the actuator, or screw down the valve stem stroke-ring with Red Loctite 542 and fix the half bearings. When the threaded holes of the actuator flange are in correspondence with the holes on the valve flange screw the proper stud bolts. Screw the nuts on the stud bolts and tighten up the valve flange is in contact with the actuator flange.

4. Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in the Table. The stud bolts must be made of ASTM A320 L7 steel, the nuts must be made of ASTM A194 grade 2 steel as minimum.

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9

8

7

6

5

4

3

2

1

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Installation

Table 2. Parts List

Item Description

1 Stud bolt

2 Nut

3 Nut

4 Screw

5 Pedestal

6 Actuator joint

7 Stem valve joint

8 Shell joint

9 Spacer

10 Screw

B. To assemble the actuator onto the valve by bracket with shell joint, perform the following operations:

Figure 6 Pedestal with Shell Coupling Joint

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Installation

1. Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions (valve stem and flange). Lubricate the valve stem with grease in order to make the assembly easier.

2. To make easier the assembly, the valve stem has to be in perfect vertical position.

3. Disassemble the two halves of actuator pedestal shell joint (item 8) by unscrewing the retaining screws (item 4), therefore disassemble the valve stem joint (item 7).

4. Lift the actuator by utilizing the proper lifting eyelets, and unscrew the nuts and the stud bolts from the actuator pedestal.

5. Assemble the actuator onto the valve, and arrange it in its correct vertical position proper to connection between valve stem and actuator cylinder rod.

6. Screw the valve stem joint (item 7) on valve stem up to reach the proper position which allow the reassembly of the two halves of shell joint (item 8), tighten the joint fastening screws (item 4).

7. Screw the stud bolts (item 1) into the actuator pedestal flange, and screw the nuts on the stud bolts.

8. Tighten according to the nut (item 2) size torque requirements.

To operate refer to following Table:

The screwing values in Table 3 were calculated considering the materials ASTM A320 L7 for screws or tie rods and ASTM A194 gr.2H for the nuts.

Table 3. Nuts Tightening Torque

Threading Tightening torque (Nm)

M8 20

M10 40

M12 70

M14 110

M16 160

M20 320

M22 420

M24 550

M27 800

M30 1100

M33 1400

M36 1700

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Installation

2.5 Pneumatic Connections

!WARNINGCheck that the values of pneumatic supply available are compatible with those reported on the identification plate of the actuator.

NOTICEThe connections should be made by qualified staff. Use pipes and connections appropriate as for type, material and dimensions.

• Properly deburr the ends of rigid pipes.

• Properly clean the interior of pipes sending through them plenty of the supply fluid used in the system.

• Mould and fasten the connection pipes so that no irregular strains at entries or loosening of threaded connections occur.

• Make the connections according to the operating diagram.

• Check the absence of leakages from pneumatic connections.

2.6 Electrical Connections (If Any)

!WARNINGUse components appropriate as for type, material and dimensions. The connections should be made by qualified staff Before carrying out any operation, cut line power off.

Safety provisions:

2006/95/EC: Directive for low voltage equipment (until 19 April 2016) 2014/35/EU from 20 April 2016

2004/108/EC: Directive for the electromagnetic compatibility (until19 April 2016) 2014/30/EU from 20 April 2016

94/9/CE: Directive and safety instructions for use in hazardous Area (until 19 April 2016) 2014/34/EU from 20 April 2016.

Remove plastic plugs from cables entries

• Screw firmly the cable glands.

• Introduce connection cables.

• Make the connections in compliance with applicable wiring diagrams on the documentation supplied.

• Screw the cable gland.

• Replace the plastic plugs of unused entries with metal plugs.

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Installation

2.7 Commissioning

!WARNINGInstallation, commissioning and maintenance and repair works should be made by qualified staff.

Upon actuator commissioning please carry out the following checks:

• Check that paint is not be damaged during transport, if necessary repair the damages to paint coat.

• Check that the pressure and quality of the gas supply (filtering degree, dehydration) are as prescribed. Check that the feed voltage values of the electric components (solenoid valve coils, micro-switches, pressure switches, etc.) are compatible with those reported on the identification plate of the actuator (Figure 1) and to specific data-plate on electric components.

• Check that the setting of the components of the actuator control unit (pressure regulator, pressure switches, flow control valves, etc.) meet the plant requirements.

• Carry out all kinds of operations and check their proper execution (Section 3.3).

• Check the absence of leakages in the pneumatic connections.

• If necessary tighten the nuts of the pipe-fittings.

• Check proper operation of all the due signalling (valve position, gas supply pressure etc.).

• Make a complete functional test in order to verify all the operations are executed according to operating schematic diagram supplied.

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Section 3: Operation and Use

Operation and Use


3.1 Operation Description

The supply gas pressurizes the pneumatic cylinder chamber, this pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled. The valve is actuated in opening and in closing position by the actuator pneumatic cylinder in one direction and by the spring unit in the other direction.

For local or remote operations, please refer to technical documentation furnished with actuators.

The power and control systems are supplied on specific customer demand.

NOTICEFor all the relevant information please refer to the specific documentation supplied.

Figure 8 Single-Acting (spring-return) actuator with jackscrew manual override type MHW (direct action) or MSJ (that it can be engaged/disengaged by hand lever)

Figure 7

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Operation and Use

Figure 9 Single-Acting (spring-return) actuator with jackscrew manual override type MHP

3.2 Residual Risks

!WARNINGIt is recommended to pipe exhaust gas. The actuator has parts under pressure. Use the due caution. Use individual protections provided for by the laws and provisions in force.

3.3 Operations

3.3.1 Local Pneumatic Operation

!WARNINGUse the proper safety measures to protect from any pressurized gas not piped and from excessive and harmful noise. Refer to applicable control schematic in supplied documentation.

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Operation and Use

Figure 10 PLAS MHP without control system

Pressurize the pneumatic cylinder chamber, this pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled.

The valve is actuated in opening and in closing position by the actuator pneumatic cylinder in one direction and by the spring unit in the other direction. Check the correct operation of the actuator through the visual position indicator.

3.3.2 Electric Remote Control to Open and to Close

When actuator is furnished of control system (panel or cabinet) remote operations were possible:

• From the control room send the electric signal corresponding to the operation to carry out : energize solenoid valve during all the valve stroke.

• Solenoid valve must be de-energized at the end of actuator operation: the actuator moves to fail safe position.

3.3.3 Emergency Manual Operation by MSJ / MHW(when sufficient line pressure is not available)

• Engage the manual override by rotating it’s handle.

• Turn by the lever the manual override clockwise to close, or counterclockwise to open.

• Check the correct operation of the actuator through the visual position indicator.

• If no other manual operation is carried out, disengaged the manual override to allow the operation with pneumatic supply.

(See Section 7.2, Table 15: sectional drawing for Manual Jackscrew MSJ.)

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Operation and Use

3.3.4 Emergency Manual Operation by MHP(when sufficient line pressure is not available)

• Select by the valve 5-D the opening or closing operation.

• Actuated the pump 5-P until to reach the complete operation

• Check the correct operation of the actuator through the visual position indicator.

• If no other manual operation is carried out, the valve 5-D must be in “remote control” position to allow the operation with gas supply.

(See Section 7.2, Table 13: sectional drawing for hydraulic control unit MHP.)

3.4 Calibration of the Linear Stroke

It is important that the mechanical stops of the actuator (and not those of the valve) stop the linear stroke at both extreme valve position (fully open and fully closed), except when this is required by the valve operation).

The setting of the open/closed valve position (upward position) is performed by adjusting the travel stop screw into the end flange of the pneumatic cylinder and by the adjustment of the coupling of valve stem to actuator joint for the downward position.

For the adjustment of the travel stop screws proceed as follows:

1. Unscrew the plug from the “adjusting screw cover”.

2. If the actuator angular stroke is stopped before reaching the upward position (fully open or closed), unscrew the adjusting screw by turning it anticlockwise with a proper wrench , until the valve reaches the right position. When unscrewing the adjustable screw, keep the “adjusting screw cover still with a wrench so it does not withdraw together with the screw.

3. If the actuator angular stroke is stopped beyond the upward position (fully open or closed valve), screw the stop screw by turning it clockwise until the valve reaches the right position.

4. Screw the plug into the “adjustable screw cover”.

Plug for adj. screw coverAdjusting screw cover

Adjusting screw

Figure 11 Mechanical Stop

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Operation and Use

For the adjustment in PLAS with hydraulic manual override the mechanical stop is placed on the end flange of hydraulic cylinder, follow these steps (Figure 12):

1. Remove with the specific wrench (c1) the plug (t).

2. Insert a wrench for Allen keys (c2) in the through hole until reaching the adjustment pin (g).

3. Keep the protection cover blocked with the special wrench (c3).

4. Turn counterclockwise to increase the angular stroke, turn clockwise to decrease it.

5. When the adjustment is over tighten the plug (t).

Table 4. Size Table

Hydraulic cylinder size Wrench C1 (mm) Wrench C2 (mm) Wrench C3 (mm)

075 22 10 36

100 22 10 36

135 22 10 36

175 22 14 46

200 27 14 46

235 27 17 65

280 27 17 65

300 36 17 110

Figure 12 Mechanical Stop of the Cylinder (for MHP version)

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Operation and Use

For the adjustment of the mechanical stop screwed on the end flange of manual override (see also Section 7.2, Table 15: sectional drawing for manual jackscrew MSJ) proceed as follows:

1. Loosen the lock nut (item 2).

2. If the actuator angular stroke is stopped before reaching the end position (fully open or closed), unscrew the stop screw (item 1) by turning it anticlockwise, and actuate the handwheel of manual override until the valve reaches the right position. When unscrewing the stop screw, keep the lock nut still with a wrench so that the sealing washer does not withdraw together with the screw.

3. Tighten the lock nut, after having correctly placed the threaded seal washer (item 3 and 4).

4. If the actuator angular stroke is stopped beyond the end position (fully open or closed valve), actuate the handwheel of manual override and screw the stop-screw by turning it clockwise until the valve reaches the right position.

5. Tighten the lock nut, after having correctly placed the threaded seal washer (item 3 and 4).

43 2 1

43 2 1

Figure 13 Mechanical Stop on the End Flange of Manual Override

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Operation and Use

3.5 Calibration of Micro-Switches (for Biffi limit switch box*)

!WARNING*If different micro-switches assembly or limit switch box is supplied, please refer to the specific documentation.

NOTICEOperate only the micro-switch corresponding to the direction of operation being carried out, as clearly reported on the micro-switch.

Micro-switches are placed inside a special box (Figure 14).For micro-switches calibration please refer to the relative wiring diagram and follow these steps:

• Unscrew the fastening screws of the cover (Figure 14).

• Remove the cover paying attention not to deteriorate the gasket and the cylindrical and flat coupling surfaces.

• Operate the actuator (in opening or closing) with local pneumatic or hydraulic operation (Section 3.3)

• Unscrew the screw of the operating cam relative to the micro-switch to calibrate and adjust it according to the settings (Figure 15).

• Tighten the screw.

• Operate the actuator and adjust any other micro-switch with the procedure already described.

• Position the cover making sure the cam-carrier shaft grips with the index dragging shaft.

• Check that the cover and the index show the proper position of the valve (Figure 16).

• Tighten the screws.

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Operation and Use

Figure 15 Cam Adjustment

Figure 16 Position Indicator and Pin for Micro-switches Box

Positon indicator (index)

Pin

If the index (Figure 16), does not signal the proper position of the valve but is turned by 90°:

• Remove the roll pin placed on the position indicator (index).

• Turn the indicator until reaching its proper positioning.

• Put the roll pin back in its position.

NOTICEEnd of stroke micro-switches should be operated before the stop of the stroke of the actuator due to mechanical stops. Adjust the relative cams properly.

Figure 14 Micro-switches Box

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Operation and Use

3.6 Calibration of the Operation Time

The calibration of the operation time is made by Biffi Italia s.r.l. according to customer requirements and to technical data sheet included in technical documentation. If necessary it’s possible to modify or reset the operating time through the flow regulation valve placed between the control valves enclosure and the pneumatic cylinder (Figure 17).

Pneumatic connection

Pneumatic connection

(Close) Screw for decrease speed

Screwdriver

(Open) Unscrew for increase speed of operation

Item 276: see operating diagram

Wre

nch

Figure 17 Adjustment of Operation Time

To carry out the adjustment, use an adequate Allen wrench and follow these steps (Figure 17):

• Loosen the lock nut.

• Screw with a screwdriver the setting screw to increase the operation time.

• Unscrew with a screwdriver the setting screw to decrease the operation time.

• After the adjustment is over screw the lock nut.

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Operation and Use

For PLAS actuator models with Manual Handpump, the operating time is adjustable through two regulation valves placed on manual handpump body (see Section 7.2, Table 13: sectional drawing for hydraulic control unit MHP).

To carry out the adjustment, use a suitable Allen wrench and follow these steps (Figure 18):

• Remove the cap nut.

• Loosen the lock nut.

• Screw with a screwdriver the setting screw to increase the operation time.

• Unscrew with a screwdriver the setting screw to decrease the operation time.

• After the adjustment is over screw the lock nut and put back in place the cap nut.

Cap nut

Setting screw

Lock nut

Figure 18 Flow Regulators Placed on Manual Handpump

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Section 4: Operational Tests and Inspections

Operational Tests and Inspections

Section 4: Operational Tests and Inspections

NOTICETo ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual.

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Section 5: Maintenance

Maintenance


NOTICEBefore executing any maintenance operation, it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator and from the control unit (if foreseen).

!WARNINGInstallation, commissioning and maintenance and repair works should be carried out by qualified staff.

5.1 Periodic Maintenance

PLAS actuators are designed to operate long-term in heavy-duty operating conditions, without maintenance needs.

NOTICEPeriodicity and regularity of inspections is particularly influenced by specific environmental and working conditions. They can be initially determined experimentally and then be improved according to actual maintenance conditions and needs.

Anyway every 2 years of operation the following is recommended:

• Check that the actuator operates the valve correctly and with the required operating times. If the actuator operation is very infrequent, carry out a few opening and closing operations with all the existing controls (remote control, local control, emergency controls, etc.), if this is allowed by the conditions of the plant.

• Check there are no hydraulic or pneumatic leakages.

• Check oil level (Figure 19) into the hydraulic manual handpump, if present (see Section 5.1.1).

• Check the actuators did not undergo accidental damage with oil leakages found on site (Section 5.1.1).

• Check that improper closing of control-group cover did not produce the presence of condensation on it.

• Check the integrity of worn out parts (gaskets, pads etc.).

• Replace, if any, the mechanical filter of the supply gas (refer to Section 5.1.2).

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Maintenance

Figure 19 Level measuring stick

5.1.1 Check and restore oil level in the hydraulic manual handpump

Operate the distributor lever to “manual operation” to operate valve and to compress completely the actuator spring.

Maximum level

Minimum level

Move the actuator into his “totally compressed spring” position.

Unscrew the dipstick (1).

Check that the oil level into the tank (4) is in correspondence of the “MAX LEVEL” notch of the dipstick.

Screw and tighten the dipstick.

If necessary substitute or added the oil, proceeding as follow:

• Remove the dipstick (1) from the tank cover (22).

• Unscrew the plug (27) and the washer (9) to drain all the oil.

• If some dirt or/and sludge is found in the oil drained from the tank, before filling with new oil in the tank, disassemble the oil tank tube, by unscrewing the two cap nuts (2), and clean the internal surfaces of the tank. If necessary substitute the gaskets (21) of the tank.

• Replace the plug (27) and the washer (9) into the plate (11) and tighten.

• Pour the new oil into the tank through the dipstick hole (1) on the cover (22).

• Replace the dipstick (1).

• Add oil (refer to Table 5) if in the tank the oil level is BELOW THE MINIMUM (Figure 19: minimum level is in correspondence to the end of dipstick ) until to reach the optimal (MAXIMUM) oil level .

• Operate the distributor lever to “Remote” position.

Figure 20

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Maintenance

Table 5. Features of Hydraulic Oil Used by Biffi Italia s.r.l.

Standard temperature conditions (-30 °C/+85 °C):

Producer AGIP

Name ARNICA 22

Viscosity at 40 °C 20.9 mm²/s

Viscosity at 100 °C 4.73 mm²/s

Viscosity index ASTM 153

Flash point 192 °C

Pour point -42 °C

Specific weight (at 15 °C) 0.857 kg/l

Equivalent oils:

SHELL TELLUS PLUS 22CHEVRON HYDRAULIC OIL AW ISO 22MOBIL DTE22EXXON UNIVIS N22EQUIVIS ZS22BP ENERGOL HLP-HM22CASTROL DYSPIN AWS22

Low temperature conditions (until -46 °C):

Manufactured SHELL

Name AEROSHELL FLUID 41

Viscosity at -54 °C 2300 cST


Viscosity at 40 °C 14.1 cST


Viscosity index (ISO 2909) >200

Flash point 105 °C

Pour point <-60 °C

Specific weight (or equivalent) 0.87 kg/dm3

Low temperature conditions (until -60 °C):

Manufactured SYNTESIS

Name SYNTRASS-CS 500





Flash point 152 °C

Pour point -68 °C

Specific weight (or equivalent) 0.897 kg/dm3

NOTICEFor refill use oil of the same brand as the one in the tanks.

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Maintenance

5.1.2 Gas Supply Dehydrating Filter Maintenance (if foreseen)

The gas supply filter is fitted with a mechanical filter and a drain valve to discharge periodically the water generated by the condensation of the humidity inside the gas supply.

During the routine maintenance it is recommended to check and clean the mechanical filter and replace it in case of heavy dirty conditions.

To disassemble the filter please consult technical documentation suitable for the component, in general:

a. close the stop valve at the inlet of pressure supply line;

b. discharge the pressure from the drain valve;

c. Remove the lover enclosure screws,

d. remove the mechanical filter;

e. clean or replace the filter;

Reinstall all parts carefully paying attention to avoid any damage to the seals.

5.2 Extraordinary Maintenance

If there are leaks in the hydraulic cylinder, pneumatic cylinder or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembled and seals must be replaced with reference to the follow general sectional drawing and adopting the following procedures.

5.2.1 Replacement of Cylinder Seals

NOTICEBefore executing any maintenance operation, it is necessary to intercept the supply line and discharge pressure from the cylinder of the actuator.

If the actuator can be operated, it is essential to take it to fail safe position, with the spring totally extended, otherwise the actuator should be disassembled from the valve and follow these steps:

• Remove the plug (36) from the cover of the adjustment screw (28).

• Record the length between end flange and stiop-setting screw, as in Figure 21 (for MHP version).

• Bring the adjustment screw back to the maximum (27) to let the spring loosen.

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Maintenance

Stop setting screw cover

Stop setting screw

Plug

!WARNINGBefore disassembling the cylinder, make sure the above operation of spring release is done.

For standard version, proceed as follow (see Figures in following pages):

1. Unscrew the plug (36) from the adjusting screw cover (28).

2. Remove the adjusting screw cover (28) together with the O-ring (26).

3. Measure the distance of the protrusion of adjusting screw (27) with reference to the end flange (25) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

4. Bring the adjustment screw back (27) to the maximum to let the spring loosen, after that removed the stop-screw from the end flange (25).

5. Unscrew the nuts (34) from the tie rods (22) from the side of the end flange: they must be gradually unscrewed all at the same time.

6. Slide off the end flange (25) and the tube (20).

Figure 21

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Maintenance

Seals replacement

Prior to reassemble check that the actuator components are in good conditions and clean. Lubricate all the surfaces of the parts, which move in contact with other components, by recommended grease (AGIP-ENI LCX 2/32 if seals are in NBR/Viton or Neoprene rubber, or with Aeroshell Grease 7 if the seals are in Fluorosilicon rubber). If the O-ring must be replaced, remove the existing one from its groove, clean the groove carefully and lubricate it with protective oil film. Assemble the new O-ring into its groove and lubricate it with a protective oil film.

1. Replace the O-ring (31) of the head flange (18).

2. Replace the O-ring (32) and the guide sliding ring (33) of the piston (24). Replace the O-ring (31) of the end flange (25).

3. Remove the O-ring (26) from the stop screw cover (28). Carefully clean and lubricate the stop screw thread and the surface of the end flange area, on which the sealing works.

4. Screw the new sealing onto the stop screw.

Reassemble

1. Carefully clean the inside of the tube (20) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate the inside surface of the tube and the bevels at the ends. Slide the tube onto the piston taking care not to damage the piston O-ring (32) and the head flange O-ring (18).

2. Assemble the end flange by centring it on the inside diameter of the tube, taking care not to damage the O-ring (31).

3. Assemble the the nuts (34) onto the tie rods (22). Tighten the nuts to the recommended torque, alternating between opposite corners.

4. Screw the stop screw (27) into the threaded hole of the end flange until it reaches its original position (the same protrusion with reference to the flange surface). To make the operation easier feed the pneumatic cylinder with air (if possible) in order to move the piston.

5. Tighten the adj. screw cover (28) and the nut (36).

NOTICECarry out a few operations (Section 3.3) to check there are no leakages from the gaskets.

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Maintenance

Item Description

1 Nut

2 Stud bolt

3 Support joint

4 Connecting joint

5 Scraper support

6 Scraper ring

7 Screw

8 Bushing

9 Flange

11 Retainer ring

12 Piston rod

13 External tube

14 Lifting eyelet

15 Internal spring

16 Piston rod guide tube

17 Upper spring flange

18 Head flange

19 Seal washer

Figure 22 PLAS with threaded coupling joint

Table 6. Parts list

Item Description

20 Cylinder tube

21 Screw

22 Screw

23 Sealing washer

24 Piston

25 End flange

26 O-ring

27 Adjusting screw

28 Adjusting screw cover

29 Lower spring flange

30 O-ring

31 O-ring

32 O-ring

33 Guide sliding piston ring

34 Nut

35 Eyebolt

36 Plug for adj. screw cover

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Maintenance

Item Description

1 Stud bolt

2 Nut

3 Nut

4 Screw

5 Pedestal

6 Actuator joint

7 Stem valve joint

8 Bushing

9 Flange

10 Screw

11 Retainer ring

12 Piston rod

13 External tube

14 Scraper ring with support

15 Internal spring

16 Piston rod guide tube

17 Upper spring flange

18 Head flange

19 Seal washer

Figure 23 PLAS with shell coupling joint

Table 7. Parts list

Item Description

20 Cylinder tube

21 Screw

22 Screw

23 Connecting device

24 Piston

25 End flange

26 O-ring

27 Adjusting screw

28 Adjusting screw cover

29 Lower spring flange

30 O-ring

31 O-ring

32 O-ring

33 Guide sliding piston ring

34 Nut

35 Eyebolt

36 Plug for adj. screw cover

37 Shell joint

38 Spacer

33



Maintenance

5.3 Dismantling and Demolition

!WARNINGBefore disassembling the actuator it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank, if present. The demolition of the actuator both concerning any electrical and mechanical parts should be made by specialized staff.

Before starting the disassembly a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by worksite.

Separate the parts composing the actuator according to their nature (ex. metallic, and plastic materials, fluids etc.) and send them to differentiated waste collection sites, as provided for by the laws and provisions in force.

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Section 6: Troubleshooting

Troubleshooting

Section 6: Troubleshooting

6.1 Failure or Breakdown Research

Table 8. Troubleshooting

Event Possible cause Remedy

Actuator does not work

Lack of power supply Restore it

Lack of pneumatic supply Open line interception valve

Blocked valve Repair or replace

Wrong position of the distributor of the hydraulic manual override

Restore correct position

Failure of the control systemCall Biffi Italia s.r.l. Customer Service

Low supply pressure Restore (Section 1.4)

Actuator too slow

Low supply pressure Restore (Section 1.4)

Wrong calibration of flow regulator valves Restore (Section 3.6)

Wear of the valve Replace

Actuator too fastHigh supply pressure Restore (Section 1.4)

Wrong calibration of flow regulator valves Restore (Section 3.6)

Leakages on hydraulic or pneumatic circuits

Deterioration and/or damage to gasketsCall Biffi Italia s.r.l. Customer Service

Incorrect position of the valve

Wrong adjustment of mechanical stops Restore (Section 3.4)

Wrong warning of micro-switches Restore (Section 3.5)

Hydraulic manual pump does not work

Handle positioned on remote controlPosition the handle on the indication of the operation to make

Leakages on the check valve of the hydraulic control group

Call Biffi Italia s.r.l. Customer Service

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Section 7: Layouts

Layouts

Section 7: Layouts

7.1 Spare Parts Order

For spare parts order to the relevant Biffi office please make reference to Biffi order confirmation concerning all the supply, and serial number of the actuator, refer to Section 1.2 for any specific spare part for a specific actuator model.

Please send every spare-parts request to:

Biffi Italia s.r.l. - Servizio Assistenza Tecnica Clienti

Tel.: 0523-944523

Fax: 0523-941885

E-mail: [email protected]

Please specify:

1. actuator model

2. Biffi acknowledgement

3. spare parts code

4. quantity

5. transport condition

6. involved people

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Layouts

Section 7: Layouts

7.2 Parts List for Maintenance and Replacing Procedure

Figure 24 Pedestal with Coupling Joint

Item Qty Description Material

1 1 Pedestal Carbon steel

2 1 Antirotation shaft Stainless steel

3 1 Plate Stainless steel

4 1 Scrape ring flange Stainless steel

5 1 Shell joint Stainless steel

6 22 Screw Stainless steel

7 1 Dowel Stainless steel

8 4 Nut Stainless steel

9 4 Stud bolt Stainless steel

10 1 Scraper ring Turcon+NBR*

11 22 Washer Stainless steel



NOTE:* Recommended spare parts

Table 9. Parts List - Pedestal with Coupling Joint

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Section 7: Layouts

Layouts

Figure 25 Pneumatic Cylinder


1 1 Head flange Carbon steel

2 8 Washer Carbon steel+nitrile rubber

3 12 Screw Alloy steel

4 1 Cylinder tube Carbon steel

5 8 Tie rod Alloy steel

6 2 O-ring Viton rubber*

7 1 Piston Carbon steel

8 1 End flange Carbon steel

9 1 Washer Alloy steel


11 1 Joint Carbon steel

12 4 Eyebolt Carbon steel

13 8 Nut Carbon steel


15 1 Guide sliding ring for piston Teflon+Graphite*


17 1 Rod bushing Steel+bz+Teflon

19 1 Rod bushing Steel+bz+Teflon


21 4 Washer Carbon steel


Table 10. Parts List - Pneumatic Cylinder

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Layouts

Section 7: Layouts


1 2 Piston rod bushing Steel+bz+Teflon

2 1 Upper spring flange Carbon steel

3 1 External flange Spring steel

4 1 Rod Stainless steel STM A564-TP 630

5 4 Retainer ring Stainless steel

6 1 Lower spring flange Carbon steel

7 2 Flange Carbon steel

8 1 External tube Carbon steel

9 1 Piston rod guide tube Nitrided carbon steel

10 1 Lifting eyelet Carbon steel

11 1 Panel support Carbon steel

12 1 External spring Spring steel

Figure 26 Spring Cartridge

Table 11. Parts List - Spring Cartridge

39


Section 7: Layouts

Layouts

Figure 27 Hydraulic Cylinder


1 1 Piston rod bushing Steel+bz+Teflon

2 1 Head flange Carbon steel

3 2 O-ring NBR rubber*

4 1 Piston rod seal ring Teflon + graphite*


6 1 Piston rod Alloy steel

7 1 Piston Nickel plated carbon steel

8 2 Guide sliding ring for piston Teflon + graphite*

9 1 Piston seal ring Teflon + NBR rubber*

10 4 Tie rod Alloy steel ASTM A320 gr. L7

11 1 Stop setting screw Alloy steel

12 1 Cylinder tube Nickel plated carbon steel

13 1 End flange Carbon steel

14 1 Stop setting screw cover Carbon steel

15 4 Spring washer Carbon steel

16 4 Nut Carbon steel ASTM A194 gr. 7


18 6 Plug Carbon steel



Table 12. Parts List - Hydraulic Cylinder


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Layouts

Section 7: Layouts

Figure 28 Hydraulic Control Unit MHP

Oil tank relief valve

Relief valve for automatic operation

Flow regulator

Relief valve for manual operation

41


Section 7: Layouts

Layouts

Table 13. Parts List - Hydraulic Control Unit MHP


1 1 Dipstick Carbon steel + Alum.


3 6 Washer Copper

4 1 Hydraulic tank Carbon steel

5 1 Handpump See attached table

6 2 0-ring Fluorosilicon rubber*

7 2 Ball Stainless steel

8 2 Spring Spring steel

9 2 Washer Copper

10 1 Screw Carbon steel

11 1 Plate Carbon steel

12 1 Flange Aluminium


14 1 Lever Carbon steel

15 1 Distributor Stainless steel

16 1 O-ring Fluorosilicon rubber*


18 1 Nozzle Carbon steel



21 2 Tank gasket Fiber*

22 1 Tank cover Carbon steel

23 2 Tie rod Carbon steel


25 1 Flange Aluminium

26 2 Check valve body Carbon steel


28 2 Flow control valve setting screw Stainless steel

29 2 Spring pin Stainless steel


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Layouts

Section 7: Layouts






34 2 Plug Stainless steel

35 2 Retainer ring Carbon steel

36 2 Spring pin Carbon steel

37 2 Rivet Aluminium

38 1 Operation instruction plate Stainless steel


40 1 Spring Stainless steel



43 1 Spring Carbon steel

44 1 Relief valve setting screw Alloy steel

45 1 Spring pin Carbon steel




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Section 7: Layouts

Layouts

Figure 29 Hydraulic Control Unit - Handpump




2 1 Delivery valve bush Carbon steel

3 1 Suction valve bush Carbon steel


5 1 Suction valve seat Carbon steel

6 1 Spring retainer ring Carbon steel

7 1 Fork Carbon steel

8 3 Pin Stainless steel

9 6 Retainer ring Carbon steel

10 1 Rod Alloy steel (chromium plated)

11 1 Body Carbon steel

12 1 Lever Carbon steel

13 1 Split pin with rope Carbon steel+nylon

14 1 Threaded bush Aluminium

15 2 Rod seal ring Teflon+graphite



Table 14. Parts List - Hydraulic Control Unit - Handpump

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Layouts

Section 7: Layouts

Figure 30 Mechanical Manual Override

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Section 7: Layouts

Layouts


1 1 Protection pipe Carbon steel

2 1 Handwheel manual override ∅1250 Stainless steel

3 1 Jack screw Carbon steel

4 1 Engagement lever pin Stainless steel


6 1 Cover gasket Fiber*

7 1 Cover Carbon steel

8 3 Cam Alloy steel

9 1 Fork Carbon steel

10 3 Spring pin Stainless steel


12 1 Cams pin Alloy steel


14 1 Thrust block ring nut Alloy steel




18 1 Body Carbon steel

19 1 Spring pin Spring steel


21 1 Ball 1/4" Stainless steel


23 1 Screw nut Bronze

24 1 Pin Carbon steel


26 1 Bush Bronze

27 2 Thrust shoulder washer Bronze

28 1 Operating instruction plate Aluminium


Table 15. Parts List - Jackscrew Manual Override MSJ

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Date Report for Maintenance Operations

Section 8: Date Report for Maintenance Operations

Section 8: Date Report for Maintenance Operations

Last maintenance operation date: (in factory, on delivery):

……… exec. by : ………… ……… exec. by : ………… ……… exec. by : …………

Next maintenance operation date: ……… exec. by : ………… ……… exec. by : ………… ……… exec. by : …………

Start-up date: ……… (in factory, on delivery)………… ……… (on plant)…………


Notes

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Biffi Italia s.r.l. Strada Biffi 16529017 Fiorenzuola d’Arda (PC)ItalyT +39 0523 944 411

VCIOM-04491-EN ©2020 Biffi. All rights reserved.

The contents of this publication are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

Spring-Return Pneumatic Linear Actuator...3 Installation, Operation and Maintenance Manual MAN 617...

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Transcript of Spring-Return Pneumatic Linear Actuator...3 Installation, Operation and Maintenance Manual MAN 617...